Food Patty Combining and Loading System

ABSTRACT

An automated system combines the output from multiple food product producing machines, and formatting the combined output into a format for packaging. A combining conveyor has a first lane and a second lane adjacent to the first lane. Plural food product producing machines output food products onto the combining conveyor. At least one, and preferably more than one, of the food product producing machines outputs food product into an onload position in the second lane. One or more shifting mechanisms shift the food product from the second lane into the first lane. The first and second lanes move together along a conveyor moving direction and each shifting mechanism is located downstream in a conveyor moving direction from the onload position.

This application claims the benefit of U.S. Provisional Application 61/033,062, filed Mar. 3, 2008.

TECHNICAL FIELD OF THE INVENTION

The invention relates to patty producing, fill and packaging apparatus. The invention relates to an apparatus that produces food products and places the food products in packaging.

BACKGROUND OF THE INVENTION

In the production of packaged food products, a typical arrangement comprises at least one food product patty former, such as a FORMAX F26, F26 ULTRA or MAXUM700 food patty forming machine, a sheet interleaving device and an output conveyor to produce a stream of stacked patties with interleaved paper separators. Examples of such food product patty formers are described in U.S. Pat. Nos. 7,255,554 and 3,887,964 and U.S. patent application Ser. No. 12/018,722, filed Jan. 23, 2008, all herein incorporated by reference. Examples of sheet interleaving devices and arrangements to interleave stacked patties are disclosed for example in U.S. Pat. No. 2,877,120; 3,126,683; 3,675,387; 3,952,478; 4,054,967 or 7,159,372, all herein incorporated by reference.

To increase production of stacks of patties, it is known to use multiple forming machines in a patty production plant.

U.S. Pat. No. 7,328,542, herein incorporated by reference discloses an apparatus for loading food product into open top trays arranged in a row and movable into a loading station. The apparatus includes a conveyor having a retractable and extendable or movable conveying surface, the conveying surface arranged above the loading station and having an end region positionable over the row of trays and retractable to deposit food products into the trays; and a pushing assembly arranged above the row of trays and adapted to push food product into the row of trays as the conveying surface end region is retracted. The apparatus includes a guide assembly arranged with the pushing assembly, the guide assembly arranged to capture the food products on the conveyor, the pushing assembly arranged to push food products from within the guide assembly into the row of trays.

The present inventors have recognized that it would be desirable to provide a system for combining the output from multiple patty forming machines and automating the packaging of the combined output of patty stacks.

The present inventors have recognized the desirability of providing a system wherein the output from multiple patty forming machines can be efficiently packaged by a single packaging machine.

The present inventors have recognized that it would be advantageous to automate the packaging of food products, particularly stacked food products from multiple patty forming machines.

SUMMARY OF THE INVENTION

The invention provides an automated system for combining the output from multiple food product producing machines, formatting the combined output and loading the combined output into packaging. The invention is particularly adapted to effectively load food product stacks into packaging.

Although the system of the invention is particularly useful for food patty forming machines, the system of the invention could also be useful for food loaf or food slab slicing machines.

The invention provides an automated system for combining the output from multiple food patty forming machines, formatting the combined output and loading the combined output into packaging. The invention is particularly adapted to effectively load formed patty stacks, each stack having patties separated by interleaved sheets, into packaging.

The system includes multiple patty forming machines having output conveyors. The patty forming machines are configured to output rows of stacked patties separated along the output conveyor transport direction. The output conveyors are arranged to transport the rows onto a combining conveyor.

The combining conveyor moves the rows of patties in a moving direction at an angle to the transport direction of the output conveyors, preferably at a substantially perpendicular angle. The combining conveyor includes a first lane and a second lane adjacent to the first lane. Both lanes are moved together in the moving direction. For at least one of the output conveyors the rows are sequentially deposited into the second lane at an onload position against a first stop and are thereafter moved in the moving direction in the second lane. The rows sequentially move in the moving direction and are stopped at a shifting position by a second stop aligned against a shifting mechanism. When there is clearance in the first lane adjacent to the row that is against the shifting mechanism, the shifting mechanism shifts the row from the shifting position to a merging position in the first lane, into the clearance. A third stop can be located adjacent to a far side of the first lane wherein the row can be shifted by the shifting mechanism against the third stop to accurately place the row onto the first lane. The row then continues in the moving direction, now in the first lane.

A releasable fourth stop can be provided between the first and second stop to delay the arrival of the row from the onload position to the shifting position.

Multiple output conveyors can feed into the combining conveyor along a length of the combing conveyor in this manner. Rows collected from multiple output conveyors can be arranged along the moving direction in the first lane in a single column by filling merging positions in the first lane using plural shifting mechanisms.

The single column of patties is moved into a formatting station. In the formatting station a second shifting mechanism alternately shifts groups of stacks in the single column into a third lane and an adjacent fourth lane. The third and fourth lane merge closely together and are transported into an accumulating and separating station that groups a grid of stacks having two columns and plural rows and transports the grid onto a loading conveyor in a loading station.

The loading station is arranged above open top trays arranged to accept the grid of patty stacks in one or more trays, preferably two side-by-side trays. The loading conveyor has a retractable and extendable or movable conveying surface, the conveying surface is arranged above the open top trays and has an end region positionable over the trays and retractable to deposit food products into the trays and a guide assembly arranged to capture the stacks of food products on the conveyor. A pushing assembly can be arranged within the guide assembly and arranged to push food products from within the guide assembly into the trays after the conveying surface end region is retracted.

The guide assembly can comprise a plurality of spaced-apart guide plates movable from an elevated position to a first lowered position to capture the food products on the conveyor, and to a second lowered position below the conveyor and adjacent to the row of open top trays.

Each guiding device can comprise a pair of guide plates that are displaceable away from each other, that are movable to open up a clearance between the facing guide plates at a bottom of the guiding device.

The apparatus can comprise movable plungers within each guiding device, the movable plungers being movable from an elevated position within the guiding device to a lowered position with respect to the guiding device to expel food product from the guiding device.

The apparatus can receive food patties from a food patty-molding machine or slices from a food product-slicing machine.

The apparatus of the invention allows for rapid loading of food products, particularly stacks of food products into product packaging. The apparatus of the invention allows for maintaining a neat verticality of the stacks being loaded into the packaging.

Numerous other advantages and features of the present invention will be become readily apparent from the following detailed description of the invention and the embodiments thereof, from the claims and from the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a fragmentary, plan view of a food product forming and packaging system incorporating the invention;

FIG. 2 is a continuation of the fragmentary, plan view of FIG. 1;

FIG. 3 is an elevational view of the apparatus of FIG. 2 taken along line 3-3;

FIG. 4 is a schematic sectional view taken generally along line 4-4 of FIG. 3;

FIG. 5 is an enlarged fragmentary plan view taken from FIG. 1;

FIG. 5A is a sectional view taken generally along lines 5A-5A of FIG. 5;

FIG. 6 is a view similar to FIG. 5 but in a further stage of operation;

FIG. 7 is a view similar to FIG. 6 but in a further stage of operation;

FIG. 8 is an enlarged fragmentary plan view taken from FIG. 2;

FIG. 8A is a sectional view taken generally along line 8A-8A of FIG. 8;

FIG. 9 is an enlarged fragmentary plan view taken from FIG. 2;

FIG. 10 is an enlarged fragmentary plan view taken from FIG. 2;

FIG. 11 is an enlarged fragmentary elevational view taken from FIG. 3;

FIG. 12 is an enlarged fragmentary elevational view taken from FIG. 3;

FIG. 13 is an enlarged fragmentary elevational view taken from FIG. 3;

FIG. 14 is an enlarged fragmentary elevational view taken from FIG. 3;

FIG. 15 is a sectional view taken generally along line 15-15 of FIG. 14;

FIG. 15A is an enlarged view taken from FIG. 15;

FIG. 16 is an enlarged view taken from FIG. 14;

FIG. 17 is an enlarged schematic view similar to FIG. 15A but showing two positions of moving parts;

FIGS. 18A-18D are schematical representations showing moving parts in progressively different positions;

FIG. 19 is a schematical cross section showing functional components of a patty forming machine;

FIG. 20A is a schematical, elevational view of a portion of the patty forming machine of FIG. 19;

FIG. 20B is a schematical, sectional view of a portion of the patty forming machine of FIG. 19;

FIG. 21 is an elevational view showing a patty forming machine and sheet interleaver forming patty stacks;

FIG. 22 is a sectional view taken generally along line 22-22 of FIG. 21;

FIG. 23 is a plan view of an alternate embodiment to the arrangement shown in FIG. 1;

FIG. 24 is a plan view of an alternate arrangement to the arrangement in FIG. 2 and is a continuation of FIG. 23;

FIG. 25A is an enlarged portion of FIG. 23 in a first mode of operation; and

FIG. 25B is an enlarged portion of FIG. 23 in a second mode of operation.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

While this invention is susceptible of embodiment in many different forms, there are shown in the drawings, and will be described herein in detail, specific embodiments thereof with the understanding that the present disclosure is to be considered as an exemplification of the principles of the invention and is not intended to limit the invention to the specific embodiments illustrated.

The Overall System

FIGS. 1-3 illustrate a food product producing and packaging system 10 of the present invention. The illustrated system 10 includes four food patty molding machine 16, 18, 20, 22. The machines 16, 18, 20, 22 feed a combining conveyor 24. The combining conveyor 24 feeds a formatting station 26. The formatting station 26 feeds a product loading station 28 that is arranged above a packaging machine 30. The components 26, 28 and 30 comprise a formatting and packaging system 802.

Although the system is described using patty forming machines it could also be adapted for use with slicing machines. The slicing machine can be of a type as described in U.S. Pat. Nos. 5,649,463; 5,704,265; and 5,974,925; as well as patent publications EP0713753 and WO99/08844, herein incorporated by reference. The slicing machine can also be a commercially available FORMAX FX180 machines, available from Formax, Inc. of Mokena, Ill., U.S.A.

The Combining Conveyor

Each machine 16, 18, 20, 22 outputs space-apart rows 34 of patty stacks 36, such as six patty stacks, that are aligned along the x-direction and the rows 34 are spaced apart along the y-direction. The x and y directions are indicated on the various figures. As illustrated, the stacks 36 are formed by square-shaped patties 37, although other shapes are also encompassed by the invention. The rows 34 are moved along the y-direction away from the machines 16, 18, 20, 22 by output conveyor 16 a, 18 a, 20 a, 22 a.

The output conveyors 16 a, 18 a, 20 a, 22 a transport the rows 34 of patty stacks 36 onto the combining conveyor 24.

The combining conveyor is illustrated in detail in FIGS. 1 and 5-7. The combining conveyor 24 includes a first section 46 that receives rows 34 from the output conveyor 16 a. The rows 34 are transported in the y direction until abutting a stationary stop 56 above a continuously moving conveyor surface 46 a which transports the rows 34 in the x direction.

In all the Figures it should be noted that although the rows 34 are drawn having stacks 36 spaced apart by gaps, once the row 34 encounters a stop in the conveyor longitudinal moving direction, the gaps will be closed as the moving conveyor continues to move the stacks 36. Also, in this regard, the stacks 36 are formed on a bottom most interleaving sheet 618 that has a coefficient of friction with the conveyor surface that allows the stack 36 to remain stationary while the underlying conveyor surface continues to move without disturbing the stack 36.

The output conveyor 18 a transports rows 34 onto a second section 48 of the combining conveyor 24. The second section 48 has a moving conveyor surface 48 a that has a width that accommodates two lanes. A first lane 50 is in alignment with the conveyor surface 46 a along the x direction. A second lane 52 is parallel to and adjacent to the first lane 50 and near to the output conveyor 18 a. A stationary stop 56 is arranged above the conveyor surface 48 a between the two lanes 50, 52. Rows 34 transported onto the surface 48 a from the output conveyor 18 a abuts the stop 56 and are transported by the conveyor surface 48 a in the x direction until abutting a movable stop or gate 60. The gate 60 holds the row 34 from moving in the x direction by the conveyor surface 48 a until a preselected time elapses or a control signal releases the gate 60 and the row 34 held thereby.

FIG. 5A shows the gate 60 being raised or lowered by an actuator 61 supported by a bracket 62 supported by the machine frame.

At the correct time, the row 34 is released by raising the gate 60 and the row 34 travels in the x direction until abutting a fixed stop 64 and is held adjacent to a shifting mechanism 66. The shifting mechanism 66 includes a plate 70 that is configured to be moved in the y direction and has a length equal to a length of the row 34 of patty stacks 36. A linear actuator 76, such as a servomotor linear actuator or a pneumatic cylinder, is selectively actuated to move the plate 70, and the row 34 aligned against the plate 70, in the y direction until the row abuts a stationary stop 72 above the conveyor surface 48 a. The row 34 is thereby shifted from the lane 52 to the lane 50.

A pair of photo eyes 77, 78 are arranged adjacent to ends of the stop 72 in the x direction. The photo eyes 77, 78 are spaced to detect a necessary clearance in the x direction of patty stacks 36 traveling within the first lane 50 from the upstream section 46 before the actuator 76 is permitted by machine control to shift the row 34 from the second lane 52 into the first lane 50. The gap between the eyes 77, 78 is set back from the ends of the stop 72 to account for the velocity of stacks in the x direction on the moving surface 48 a.

For example, FIG. 5 illustrates a condition wherein the actuator 76 could shift the row 34 to the stop 72 there being clearance of patty stacks between the eyes 77, 78. FIG. 6 illustrates a condition where machine control would not allow shifting by the actuator 76 because of the presence of patty stacks 36 between the eyes 77, 78. FIG. 7 illustrates the row 34 shifted by the actuator 76 from the lane 52 to the lane 50. After the shift, the plate 70 is retracted to its position shown in FIG. 5 and the gate 60 is then raised to transport a new row 34 on the conveyor surface 48 a to the stop 64 against the plate 70.

The section 48 feeds in the x direction into a section 80 of the combining conveyor 24. The section 80 of the combining conveyor receives rows 34 from the output conveyor 20 a. The section 80 of the combining conveyor feeds in the x direction into a section 84. The section 84 receives rows 34 from the output conveyor 22 a. The configuration and operation of the section 80 and the output conveyor 20 a and the section 84 and the output conveyor 22 a are identical to the configuration and operation of the section 48 and the output conveyor 18 a. The same respective parts and components carry the same reference numbers and their operation need not be described.

The first lane 50 of the last section 84 feeds into a single lane conveyor 90. The single-lane conveyor 90 can have sections along its length that can be operated at progressively slower speeds between the combining conveyor 24 and the formatting station 26 to more closely space the rows 34 of patty stacks received thereon in a single column.

An end of the single-line conveyor 90 feeds patty stacks 36 in a substantially continuous column, onto an input conveyor 91 between stationary guides 91 a, 91 b in the formatting station 26.

The Formatting Station

The formatting station 26 is shown in FIGS. 8-12. Formatting station 26 formats the single column of patty stacks from the conveyor 91 into two columns. The conveyor 91 is continuously driven by a motor 89. The single column of stacks from within the guides 91 a, 91 b is stopped by a stop 92 on a moving format conveyor 114. A sweep mechanism 106 reciprocates in the x direction and alternately pushes groups of patty stacks into parallel, spaced apart lanes 110, 112 of the format conveyor 114. Although in this illustrated embodiment the groups of patty stacks comprise four stacks each, other numbers for the groups such as five patty stacks are encompassed by the invention. The sweep mechanism 106 includes a linear actuator 107, such as a servomotor linear actuator, that drives an overhead rod 108 that moves a vertically oriented sweep plate 109. As illustrated in FIGS. 8 and 8A, the rod 108 moves the plate 109 from position A to position B to move the group of stacks 36 from a center lane 111 of the conveyor 114 into the lane 112 and thereafter from position B to position C to position D to move a new group of stacks 36 into the lane 110. The plate 109 is alternately moved back and forth to form two columns of stacks 36 such as by four stacks at a time. The conveyor 114, including the lanes 110, 111, 112, is driven at a common speed by a gearbox and motor 113. The lanes 110, 112 thereafter converge in the x direction by way of stationary guides 110 a, 110 b.

A first staging conveyor 118 has a first lane 120 driven by a motor 122 and a second lane 124 driven by a motor 126. After the first lane 120 receives the group of stacks 36 from the lane 110 of the conveyor 114, the motor 122 stops until the group of stacks 36 are received on the second lane 124 from the lane 112 of the conveyor 114. Thereafter, a motor 128 drives a second staging conveyor 130 which, along with the operating motors 122, 126 and the conveyor 118, receives the two groups of stacks 36 from the lanes 120, 124 in a closely arranged array 129 or grid pattern onto the conveyor 130.

A motor 132 then drives an off load conveyor 138 that, together with the motor 128 and conveyor 130 receives the grid 129 of eight stacks onto the off load conveyor 138 spaced apart from a previous grid 129 of eight stacks 36.

Cleanup and maintenance positions of the off load conveyor 138 are shown as 138 a, 138 b.

Package Loading Station

FIGS. 12-18D illustrate the loading station 28.

In the loading station 28, a shuttle conveyor 140 having a conveying surface 140 a retracts to an upstream position and receives the grid 129 of patty stacks from the output conveyor 138. The off load conveyor 138 and the shuttle conveyor 140 are circulated at a same speed to off load the grid 129 row by row from the off load conveyor 138 onto the conveyor 140. Once the grid 129 is received on the conveyor surface 140 a, the conveyor 140 shuttles forward to a position wherein the grid 129 is in a position such that each longitudinal column of the grid 129 containing four stacks 36 is above an open tray 160 of the packaging machine 30.

Guides 144, 146 are descended to support the respective two columns of four patty stacks on the surface 140 a and the conveyor is then shuttled rearward to remove the conveyor 140 from beneath the grid 129, wherein the two columns of stacks are prevented from falling by being gripped on sides thereof by the guides 144, 146. The guides 144, 146 are further descended to hold the columns of stacks just above the open faces of the trays 160 and the pushers 148 are then descended within the guides 144, 146 to push the columns of patty stacks into the open trays 160 of the packaging apparatus. The guides and the pushers are then retracted upwardly to an elevated position above the space allocated for the conveyor 140. In the meantime a new grid 129 of patty stacks is off loaded from the conveyor 138 onto the conveyor 140, the conveyor 140 is shifted forwardly and the tray loading process is repeated.

The conveyor 140 includes a frame 140 d that is connected by members or brackets 149 a, 149 b to carriages 150 a, 150 b. The carriages 150 a, 150 b are guided for shuttling, sliding movement along linear bearings or rails 151 a, 151 b which allow the conveyor 140 to shift between a forward position for loading the grid 129 into trays 160 and a retracted position with the end 140 b being adjacent to the end 138 c of the off load conveyor 138 for loading a new grid 129 onto the conveyor 140. The carriages 150 a, 150 b are connected by clamp fasteners 152 a, 152 b to indexing belts 154 a, 154 b by that are selectively circulated together by a servomotor (not shown) to translate the carriages 150 a, 150 b, and hence the conveyor 140 longitudinally in either selected direction.

In operation, the indexing belts 154 a, 154 b driven by a motor are circulated to move the conveyor 140 to the right in FIG. 12 until an input end 140 b is adjacent to an output end 138 c of the output conveyor 138 as shown in FIG. 12. The conveyor surface 140 a is circulated to receive a grid of stacks from the circulating output conveyor 138. The indexing belts 154 a, 154 b are operated in reverse to shift the shuttle conveyor 140 to the left from the position shown in FIG. 12 to the position shown in FIG. 16. At these positions, the loading apparatus 168 can cause the guides 144, 146 to descend and clasp the two columns of stacks.

The shuttle conveyor is similar to the shuttle conveyor described in FIG. 13 and related description in U.S. Pat. No. 7,328,542.

One loading apparatus 168 is shown in FIGS. 14-16 arranged above the conveying surface 140 a and the open trays 160 provided by the packaging apparatus 30. If the loading apparatus is desired to load both trays 160 always at the same time, only one loading apparatus 168 is needed. It would be possible to provide an independent loading apparatus if desired for each column of stacks of the grid 129, and for each tray 160, but only one loading apparatus 168 is herein described. The loading apparatus 168 of the preferred embodiment is similar to the loading apparatus described in FIGS. 15-20 and related description in U.S. Pat. No. 7,328,542 except that only two guide plates 170, 172 are used instead of four guide arms, for each guide; the guide plates are longitudinally elongated compared to the guide arms of U.S. Pat. No. 7,328,542; the guide plates guide and clamp to support a column of stacks 36; plural guides are not needed to be actuated in sequence row by row; a single pusher 148 pushes plural stacks out from between the guides; and the loading apparatus is oriented 90 degrees in a horizontal plane with respect to the conveying direction of the shuttle conveyor from the orientation of the loading apparatus shown in U.S. Pat. No. 7,328,542. Otherwise, the components for raising and lowering the guides and pusher 148 are substantially similar.

The loading apparatus 168 is arranged above the open top trays 160, shown in FIGS. 14-16. The machine housing includes walls 188, 189 that are connected by a base plate 190. An elevated support plate 191 is fixedly supported by posts 192, 193 from the base plate 190. Two main pneumatic cylinders 194, 195 are mounted to the elevated support plate 191 and include rods 196, 197 that are fastened to a movable intermediate plate 198 by fastener plate assemblies 199, 200. The fastener plate assemblies 199, 200 can include length adjustable connections between the rods 196, 197 and the movable intermediate plate 198.

A movable drive plate 202 is located below the intermediate plate 198. Two guide cylinders 204, 206 are mounted to the intermediate plate 198 and include rods 205, 207 fastened to the drive plate 202 by fastener plate assemblies 208, 209 that can include length adjustable connections between the rods 205, 207 and the drive plate 202.

A plunger drive plate 210 is located above the intermediate plate 198. A plunger cylinder 211 is mounted to the plunger drive plate 210 and includes a rod 212 fastened to the drive plate 202 such as by a length adjustable fastener plate assembly 213 similar to the fastener plate assemblies 208, 209.

Within each guide 144, 146 is a reciprocal plunger 148. Each plunger 148 is preferably an elongated element that is supported on two spaced-apart plunger rods 214, 216, the plunger rods fastened at upper ends to the plunger drive plate 210. The rods 214, 216 are arranged to slide vertically through bearings fit into the plates 202, 190.

The guiding devices 144, 146 are arranged side-by-side and each are supported by a support plate 220. Each support plate 220 is fixed to bottom ends of a pair of rods 222, 224 by fasteners. The rods 222, 224 are connected at top ends thereof by fasteners to the drive plate 202. The rods 222, 224 are arranged to slide vertically through bearings fit into the base plate 190.

A lift plate 226 is arranged above each support plate 220. A pair of vertical rods 230, 232 are fastened to each lift plate 226. The rods 230, 232 are arranged to slide vertically through bearings fit into the base plate 190.

Each pair of rods 230, 232 extend up and are connected to a pair of pneumatic cylinders 234, 236 which act on the rods to selectively lift or lower the rods 230, 232. The pneumatic cylinders 234, 236 are fastened to the drive plate 202 to move therewith.

Each guide plate 170, 172 has three lugs 237 welded thereto and spaced apart along a length of the guide plates 170, 172. The lugs 237 are pinned to the support plate 220 and to the links 238. The links 238 are pinned to the lift plate 226.

The guides 144, 146 include opposing guide plates 170, 172. The guide plates have a length equal to a column length of four stacks 36. The guide plates spread apart before being lowered to capture a column of four stacks 36 on the conveyor belt surface 140 a, and thereafter are closed against the column of stacks 36 and lowered further to guide the stacks into open trays 160, assisted by the plungers 148 and arranged within and between the guide plates 170, 172.

FIG. 17 illustrates the operation of the guide device, which is typical of both guide devices 144, 146. On the right side of FIG. 17 the guide device is shown with the guide plate in a closed orientation such as when a stack has been captured on the conveyor belt. In this orientation, the pneumatic cylinders 234, 236 have lowered the rods 230, 232 and the lift bar 226 is at a lowered position with respect to support plate 220. To open up the guide plates 170, 172, and viewing the left side of FIG. 17, the pneumatic cylinders 234, 236 raise the rods 230, 232 which raises the lift bar 226 as shown. Once the lift bar is raised, the links 238 are pulled upwardly and angled to the orientation shown. The links 238 pivot and draw inward the top ends of the lugs 237 which open up the guide plates 170, 172. The guide plates pivot about pins to be spread apart at bottoms thereof.

It should be noted that in FIGS. 17, 8B and 8C the guide plate 172 or guide plates 170, 172 appear to overlap the stack 36 held thereby. In actuality, the guide plate only grips an outside of the stack 36, the overlap is shown to demonstrate a range of motion of the guide plate. The actual clamping force of the guide plates 170, 172 on the column of stacks is determined by a pressure regulator on the actuator.

In operation, as shown in FIGS. 16 and 18A-18D, the guide plates 170, 172 of each guide device 144, 146 are spread open at their bottom ends by action of the pneumatic cylinders 234, 236 driving the lift bar 226 vertically away from the support plate 220 as seen in FIG. 18A.

The main cylinders 194, 195 then lower the guide plates 170, 172 and the plunger 148 together to capture a longitudinal column of food product stacks 36 on the conveyor belt 140 as seen in FIG. 18B. The guide plates 170, 172 and the plunger 148 are driven downward by action of the pneumatic cylinders 194, 195 extending their respective rods 196, 197 to drive the plate 198 a distance from the vertical position of the elevated support plate 191.

After the shuttle conveyor 140 is retracted from below the stacks 36, the guide plates 170, 172 hold the stacks elevated above the trays 160. The guide cylinders 204, 206 are then actuated to drive the drive plate 202 further from the intermediate plate 198 and in so doing drives the guide plates 170, 172, the captured column of stacks 36 and the plunger 148 together below the elevation of the vacated conveying surface 140 a and close to an open top of the tray 160 as seen in FIG. 18C.

The plunger 148 is then driven with respect to the plates 170, 172 and further downward to dispense the stacks 36 out from between the guide plates 170, 172, to place or push the stacks 36 into the open top tray 160 as seen in FIG. 18D. The plunger 148 is driven by action of the pneumatic cylinder 211, wherein the rod 212 is retracted into the cylinder 211 to drive the cylinder 211 and the plate 210 downward with respect to the drive plate 202.

The plunger drive plate 210 vertically passes the plate 198. This passing is made possible by the plate 198 having a rectangular void on a back side thereof which allows the plate 210 to pass vertically behind the plate 198.

Once the guide plates 170, 172 clasp the column of stacks, the conveyor 140 can be retracted to the right to remove support for the columns of stacks 36 which are momentarily supported by being clasped by the guide plates 170, 172. The guides 144, 146 with the columns of stacks held thereby then descend and subsequently the plungers 148 descend to push the stacks into the open trays 160 as illustrated in FIGS. 18A-18D.

As can be seen in the figures, wherever rods penetrate plates and are movable with respect thereto, a plastic bushing, sleeve, bearing or guide is provided to reduce friction and noise, and to ensure smooth operation of the apparatus.

Although pneumatic cylinders are used in the exemplary embodiments to cause movement of the guide cylinders and plungers, such pneumatic cylinders could be replaced with a variety of types of drives all within the scope of the invention. Servo motor drives, hydraulic drives, linear actuators, and other drives are all encompassed by the invention.

A central controller can be used to coordinate the loading apparatus, particularly the movements of the guide plates and the plungers instigated by the pneumatic cylinders. An electronic-to-pneumatic interface is pneumatically connected to the pneumatic cylinders, and electronically signal-connected to the central controller. Based on a precise positioning attributes of the servomotors, the pneumatic cylinders can be precisely triggered by the central controller to be in synchronism with the position of the stacks 36 being transported on the shuttle conveyor 140. The central controller also can communicate with the packaging apparatus 30 coordinating movement of the web to deliver new open top trays 160 to the filling station 28.

The Packaging Apparatus

The packaging apparatus 30 comprises a reel system 240 that dispenses a plastic web 242, a tray forming station 250, and a tray loading position 258. The tray loading position is located within the package loading station 28. The plastic web 242 is continuous through the tray loading position 258. In the tray forming station 250 two side-by-side trays are formed, for the illustrated example two trays for holding a pair of columns of four patty stacks are formed. After the trays 160 are sufficiently solidified or cooled after forming in the forming station 250, the web 242 is indexed to remove filled trays from the loading position 258 and to position empty trays 160 from the tray forming station 250 to the loading position 258.

A tray top sealing station 266 applies a film lid 268 over the trays 160 after stacks 36 have been loaded into the trays. The film lid 268 is produced from a plastic web 270 dispensed from a reel system 272.

The Patty Forming Machines

The patty molding machines 16, 18, 20, 22 can be of known types including those described in U.S. Pat. Nos. 7,255,554 and 3,887,964 and U.S. patent application Ser. No. 12/018,722, filed Jan. 23, 2008, all herein incorporated by reference.

A well-known patty-forming machine 16, 18, 20, 22 will be described and illustrated in FIGS. 19-22. The machine 16, 18, 20, 22 includes a food supply means 300 and an associated hopper 302. A conveyor belt 306 extends completely across the bottom of the hopper 302, around an end roller 310 (or 312) and a drive roller 312 (or 310), the lower portion of the belt being engaged by a tensioning idler roll 314. A drive is provided for drive roller, driven by an electric motor (not shown).

In FIG. 19 a limited supply of meat 320 is shown present in hopper 302. A much greater supply of meat could be stored in hopper without exceeding its capacity.

The forward end of the hopper 302 communicates with a vertical pump feed opening 326 that leads downwardly into a pump intake chamber 328. A frame 332 is mounted on a machine base 338, extending over hopper adjacent the opening 326. A mounting bracket 340 is affixed to the upper portion of frame 332, extending over the pump feed opening in hopper.

When machine is in operation, feed screw motors 344 are energized whenever a food pump plunger 350 is withdrawn, so that feed screws 354 and supply meat from the hopper 302 downwardly through opening 326 and into the intake of the food pumping system. As the supply of food material in the outlet of hopper is depleted, conveyor belt 306 continuously moves the food forwardly in the hopper and into position to be engaged by feed screws 354.

A typical pump system comprises two reciprocating food pumps 360 (one shown) mounted upon the top of machine base 338. The pumps 360 are operated alternately so that when food material is depleted in one pump the alternate pump can be operated to ensure a substantially continuous production. Each food pump includes a hydraulic cylinder 364. The piston in cylinder (not shown) is connected to an elongated piston rod; the outer end of piston rod is connected to a large plunger 350. Each plunger 350 is aligned with a pump cavity 370 formed by a pump cavity enclosure 372 that is divided into two chambers by a partial central divider wall. The forward wall of pump cavity 370 has a relatively narrow slot 376 that communicates with a pump manifold 380.

The operating pump compresses the food product in pump cavity 370, forcing the moldable food material through slot 376 into manifold 380. As operation of molding machine continues, the hydraulic cylinder 364 advances the plunger 350 to compensate for the removal of food material through the manifold 380. The pump feed manifold 380 comprises a manifold valve cylinder 386 fitted into an opening in housing immediately beyond the pump cavity walls. The valve cylinder 386 is controlled to pass pressurized food product alternately from only one of the two food pumps at a time.

The upper surface of the housing that encloses the pump cavities 370 and the manifold 380 comprises a support plate 400 that projects forwardly of the housing, and that affords a flat, smooth mold plate support surface 401. A mold plate 420 is supported upon mold plate support surface 401. The mold plate 420 includes a plurality of individual mold cavities 426 extending across the width of the mold plate and alignable with the manifold outlet passageway 430. The cavities 426 are preferably square-shaped and are arranged in a row of six across the mold plate 420. However, any other number, size or shape of cavity is also encompassed by the invention.

A cover plate 434 is disposed immediately above the mold plate 420, closing off the top of each of the mold cavities 426 for much of the travel of the mold plate. A housing 438 is mounted upon cover plate. The spacing between cover plate and support plate is maintained equal to the thickness of mold plate by support spacers mounted upon support plate; cover plate rests upon spacers when the molding mechanism is assembled for operation.

The mold plate 420 is connected to a pair of drive rods 450 (one shown) that extend alongside the housing and are connected at one end to a pair of swing links 452 (one shown). The other ends of the links 452 are pivotally connected to rocker arms 456 which form a crank pivoted on a shaft 460. The free end of a crank arm 462 is provided with a lost motion connection, entailing a pin in an elongated slot, to a connecting rod assembly 466 that includes a hydraulic shock absorber. Shock absorber is connected to a mold plate crank arm 468 having a crank pin 470 linked to the output shaft 474 of a gear reducer 480. Gear reducer is driven through a variable speed drive actuated by a mold plate drive motor (not shown).

The molding mechanism further comprises a knockout apparatus 500. The knockout apparatus comprises knockout cups 506, which are affixed to a carrier bar 510 that is mounted upon a knockout support member 511. Knockout cups are coordinated in number, shape and size to the mold cavities 426 in mold plate 420; there is one knockout cup aligned with each mold cavity and the mold cavity size is somewhat greater than the size of an individual knockout cup.

Knockout support member is carried by two knockout rods 512. Each knockout rod is disposed in a housing and is pivotally connected to its own knockout rocker arm 516.

Each knockout rocker arm 516 is pivotally mounted upon a shaft 520. There, one or more springs 522 are connected to each knockout rocker arm 516, biasing the arm toward movement in a clockwise direction. Clockwise movement of each rocker arm is limited by a stop 526 aligned with a bumper mounted in housing.

Each rocker arm 516 is normally restrained against counterclockwise movement by engagement with a knockout cam 530; the two cams each have a notch 532 aligned with the corresponding notch on the other cam. Cams 530 are affixed to a knockout cam shaft 534. Shaft extends across housing to a right angle drive connection leading to a knockout cam drive shaft that has a driving connection (not shown) to the mold plate drive gear reducer output shaft.

In each cycle of operation, knockout cups are first withdrawn with cams pivoting knockout rocker arms to their elevated positions to lift the knockout cups. The drive linkage from gear reducer to mold plate then slides the mold plate from the full extended position to the mold filling position, with the mold cavities aligned with passageway. In the retracted cavity filling position for mold plate, drive rod is shown in the dash line position; the other drive components are in the positions indicated by swing link, crank arms, and connecting rod. The lost motion connections in the drive linkage assure some dwell time at the discharge or knockout position of mold plate, so that the knockout cups have time to enter and leave the mold cavities while mold plate is at rest. Some dwell at the cavity filling position may also be provided. Hydraulic cushion allows crank to pick up the mold plate load over several degrees of rotation, gradually overcoming the mold plate inertia. The lost motion connections and the hydraulic cushion incorporated in the drive linkage for the mold plate thus reduce wear and tear on both the mold plate and its drive, assuring long life and minimum maintenance.

During most of each cycle of operation of mold plate, the knockout mechanism remains in the elevated position, with knockout cups clear of mold plate. When mold plate reaches its extended discharge position, however, the notches in the cams are brought into alignment with the knockout rocker arms. At this point in the molding cycle, the two knockout rocker arms are pulled rapidly downwardly by the springs, pivoting the two rocker arms in a clockwise direction. This movement of the rocker arms drives the knockout rods downwardly, moving the knockout cups through the mold cavities to discharge molded food patties, such as the patty 550, from the mold plate.

The Sheet Interleaver

Each patty molding machine 16, 18, 20, 22 is outfitted with a sheet interleaving device 600 such as disclosed in U.S. Pat. No. 2,877,120; 3,126,683; 3,675,387; 3,952,478; 4,054,967 or 7,159,372, all herein incorporated by reference.

FIGS. 21-22 illustrate the sheet interleaver device 600 connected to the output side of each food patty-molding machine 16, 18, 20, 22.

The sheet interleavor device 600 illustrated is more completely described in U.S. Pat. No. 7,159,372. The interleavor device 600 includes a vacuum transfer shuttle 602. The vacuum transfer shuttle includes a sheet-receiving vacuum bar 604 which extends between, and is fastened to, shuttle carriages via mounting plates. The shuttle vacuum bar defines a row of openings 606 through the shuttle. Suction grippers are located on the upper surfaces of the vacuum bar and more or less surround the periphery of each opening. The suction grippers are formed by outlets connected to vacuum channels extending within the vacuum bar. The vacuum channels are connected at inlets to vacuum supply lines. The location of the vacuum grippers thereon are such that the vacuum grippers and projections will support the corners of thin, flexible sheets 618 placed on the vacuum shuttle while allowing passage of patties 550 produced by the food patty-molding machine through the openings 606.

A sheet feeder 620 is equipped with a number of inclined hoppers, one for each patty cavity in the mold plate. In this embodiment, there are six hoppers, corresponding to the six food patty cavities 426. A stack of thin, flexible sheets 618 is stored in each hopper with the sheets 618 substantially standing on edge at an angle to vertical and held in the hopper by stops located at each corner and on the sides of an open face at the lower end of each inclined hopper. Blades at the top and bottom of this open face engage the top and bottom center of the end sheet.

A sheet transfer mechanism 626 is arranged for placing thin, flexible sheets 618 from the hoppers onto the vacuum transfer shuttle in alignment with the rectangular groupings of the vacuum grippers, to cover the openings.

A number, in this case six, of releasable sheet holders or suction devices each remove a single sheet each cycle from a hopper and deposit the sheets on the vacuum transfer shuttle. The sheet holders each include a pair of suction or vacuum cups. The vacuum cups are formed of a soft flexible material, such as soft rubber. Each cup is mounted on the end of a common suction plate. The suction plate is clamped at opposite ends to a cross shaft. The suction cups are spaced in pairs along the plate so that two suction cups will engage each sheet at the open face of each hopper, with the suction cups contacting the bottom portion of the sheet, wherein each cup is located above the lower stops and outwardly of the knives. Alternately four suction cups in a grid pattern can be used to engage each sheet.

The row of knock-out cups 506 are mounted above the vacuum sheet applicator with each cup aligned with a cavity 426 in the mold plate, when the mold plate is in its outwardly extended, knock out position. Upon downward movement, the cups 506 force the food patties 550 out of the cavities 426 of the mold plate. While following these paths, each food patty engages a sheet 618, moves through an opening 606 of the vacuum bar, and lands with the supporting sheet on the respective conveyor 16 a, 18 a, 20 a, 22 a or on a previously deposited patty 550 on the conveyor, eventually forming a completed stack 36. When the stack is completed, the output conveyor 16 a, 18 a, 20 a, 22 a transports the stacked patties 36 with interleaved sheets to the combining conveyor 24.

During operation, the individual movements of the suction plate, the shuttle and the mold plate are substantially as described in U.S. Pat. No. 3,952,478. However, in that patent, the movements of the suction cups, and the shuttle that transfers the sheets to the knock out station, are mechanically linked to the movement of the mold plate and the knockout cups. Alternately the movements of the suction cups and the shuttle can be driven by one or more servomotors as described in U.S. Pat. No. 7,159,372.

The servomotor or servomotors drive the shuttle 602 into reciprocation in reverse synchronism with the reciprocating mold plate 420. The shuttle 602 with sheets 618 carried thereby is placed below the knockout cups 506 and knocked out patties 550 pass through the shuttle 602 carrying away the sheets 618 down to the respective conveyor 16 a, 18 a, 20 a, 22 a, and thereafter the shuttle 602 is reciprocated away from the mold plate 420 to receive new sheets 618 from the mechanism 626 which has removed new sheets 618 from the sheet supply hopper 620. This process is then repeated. In this way stacks of patties 36 with interleaved sheets are formed on the output conveyor 16 a, 18 a, 20 a, 22 a.

The motors described herein can all be servomotors to precisely coordinate movements of conveyors and apparatus. A central control can be programmed to control the traffic of stacks 36 from the patty formers, on the output conveyors, the formatting conveyors and formatting apparatus, the loading conveyors and loading apparatus, and the packaging machine by closely controlling and coordinating the speeds of servomotors or servo-actuators on all the equipment. In this way it is possible that some stops, such as the stop 60 and perhaps the eyes 77, 78 could be eliminated or only used as back up control.

FIGS. 23-2B illustrate a further embodiment of the invention. This embodiment incorporates the description above with respect to FIGS. 1-22 except as described herein.

In this embodiment, a modified combining conveyor 800 feeds patty stacks to a pair of formatting and packaging systems 802, 804. The system 802, 804 operate as described above and include a formatting station 26, a loading station 28 and a packaging apparatus 30.

The forming machines 16, 18, 20, 22 include the output conveyors 16 a, 18 a, 20 a, 22 a, that feed the modified combining conveyor 800 that is also fed by output conveyors 816 a, 818 a, 820 a of patty forming machines 816, 818, 820. As illustrated, the machines 16, 18, 20, 22 form rows 34 of six patty stacks 36. The machines 816, 818, 820 form rows 834 of five patty stacks 836. For example, the patty stacks 36 can comprise 1.8 ounce square meat patties while the patty stacks 836 can comprise 4.0 ounce square meat patties.

The combining conveyor 800 includes sections 846, 848, 850, 852 that transport rows 34 to the right in FIG. 23 to the formatting and packaging system 802 in a first mode of operation, and sections 860, 862, 864 transport rows 834 to the left in FIG. 23 to the formatting and packaging system 804 in the first mode of operation.

Rows 34 are transported onto the conveyor 90 to the formatting station 26 as described above. The formatting station 26 is configured to format the incoming single column of stacks 36 into a two column, five row array or grid 190 for packaging into two side-by-side trays 160, as described above. The formatting station 26 feeds the grid 129 to a loading station 28 as described above.

The rows 834 are transported by conveyor 890 that functions identically to the conveyor 90 to combine the rows 834 into a single column of patty stacks 836 that are input into a second formatting station 26 that operates identically to the formatting station 26 except the formatting station 826 is configured to create two columns, four row array or grid pattern 929 for packaging into two side-by-side trays 160, as described above. The formatting station 26 feeds the grid 929 to a loading station 28 as described above.

The trays 160 filled with stacks from the grids 129, 929 are moved thought the lid applying station and then are further conveyed away to be boxed and/or for shipping.

FIG. 25A shows further enhancements which could also be incorporated as applicable to the embodiment described above in FIGS. 1-22. The section 846 will be described. The section 846 is configured substantially identically to the sections 848, 850, 852, 860, 862 and 864 except as noted.

The section 846 includes a transport conveyor surface 846 a. Sections 848, 850, 852 each include a respect transport conveyor surface 848 a, 850 a, 852 a. The transport conveyor surfaces 846 a, 850 a, 852 a together comprise the lane 50 as previously described that is in alignment with and moves stacks 36 to the conveyor 90. Sections 860, 862, 864 each include a respect transport conveyor surface 860 a, 862 a, 864 a. The transport conveyor surfaces 860 a, 862 a, 864 a together comprise a lane 880 that functions identically to lane 50 but moves stacks 836 but is in alignment with and moves stacks 836 to the conveyor 290.

Each of the output conveyors feeds a short transport conveyor that feeds a support adjacent to a shifting mechanism.

A short transport conveyor 856 provided at an end of the output conveyor 16 a is illustrated. The transport conveyor 856 moves rows 34 deposited thereon in the x direction onto a support 857 of closely-spaced free rollers, the rollers 858 have rotary axes parallel to the y direction. The support 857 is located adjacent to the shifting mechanism 66. The row 34 is stopped by the stationary stop 64. Once a row 34 is deposited on the support 857, the actuator 76 can be actuated to shift the row 34 from the support 857 into the lane 50 against the stop 72. The row is then transported on the lane 50 to the right in FIG. 25A.

An additional optical sensor 879 can be provided between the optical sensors 77, 78 that provides further reliability of sensing of patty stacks located on the lane 50.

A gate 60 can be provided between each of the stops 56 and the support 857 if needed.

So far described, the sections 846, 848, 850, 852, 860, 862, 864 are identically configured except the sections 846-852 transport stacks to the right to the system 802 and the sections 860-864 transport stacks to the left to the system 804. However, the sections 846, 860 include an additional feature. The sections 846, 860 are reversible in feed direction so that rows of stacks produced by the machine 16 can be transported to the system 804 or rows of stacks produced by the machine 816 can be transported to the system 802. Thus production flexibility can be achieved depending on production demand for a particular size patty or for compensating for the occurrence of a particular machine being out of service.

For example, if it was desired that patty stacks from the machine 16 be sent to the system 804, before the section 846 is reversed in operation, the machine 16 is reconfigured to produce the same size patty in rows 834 as produced by the machine 816, so that the patty is compatible with the formatting and packaging system 804. The stop 56 would be reversed so that an end stop portion 56 a would be moved to the right side.

An alternate shifting mechanism 866, to the left of the short transport conveyor 856, identical to the shifting mechanism 66, would be made operable. The conveying surface 846 a, of combining conveyor section 846, would be reversed in direction of movement to transport rows to the left in the x direction and the conveyor 856 would also be reversed to move rows to the left in the x direction. A gate 60 can also be provided between the support 857 and the stop 56 if needed.

Each row 834 from the output conveyor 16 would be moved to the left onto the support 857 until the row abuts the stop 64. The actuator 76 of the shifting mechanism 866 shifts the row 834 onto the conveyor surface 846 a into the lane 50 which would move to the left (for section 846 only). The row 834 moves onto the conveying surface 860 a, into the lane 880 and deliver stacks 836 to the system 804.

In a similar fashion, the machine 16 can remain configured as shown in FIG. 25A and the machine 816 could be configured to deliver patty stacks to the system 802.

The section 860 would be reversed as demonstrated in FIG. 25B. As illustrated, the output of machine 816 is reconfigured to produce patty size compatible with the system 802. The transport conveyor 856 fed from the output conveyor 860 a is reversed to transfer rows 34 to the right in the x direction. The stop 56 is reversed for the end stop portion 56 a to be on the left side.

An alternate shifting mechanism 866, to the right of the short transport conveyor 856, identical to the shifting mechanism 66, would be made operable. The conveying surface 860 a, of combining conveyor section 860, would be reversed in direction of movement to transport rows 34 to the right in the x direction and the conveyor 856 would also be reversed to move rows 34 from the output conveyor 816 a to the right in the x direction. A gate 60 can also be provided between the support 857 and the stop 56 if needed.

Each row 34 from the output conveyor 816 a would be moved to the right onto the support 857 until the row abuts the stop 64. The actuator 76 of the shifting mechanism 866 shifts the row 34 onto the conveyor surface 860 a into the lane 880 which would move to the right (for section 860 only). The row 34 moves onto the conveying surface 846 a, into the lane 50 and deliver stacks 36 to the system 802.

According to this embodiment, the conveying surfaces 846 a and 860 a are driven independently from the conveying surfaces 848 a, 850 a, 852 a, 860 a, 862 a, 864 a, and are reversible. The short transport conveyors 856 are all driven independently and the two short transport conveyors 856 that are adjacent to the output conveyors 16 a, 816 a are reversible in operating direction. The rollers 858 need not be driven, they can be free rolling only.

From the foregoing, it will be observed that numerous variations and modifications may be effected without departing from the spirit and scope of the invention. It is to be understood that no limitation with respect to the specific apparatus illustrated herein is intended or should be inferred. 

1. An automated system for combining the output from multiple food product producing machines, and formatting the combined output, comprising: a combining conveyor having a first lane and a second lane adjacent to said first lane; plural food product producing machines outputting food products onto the combining conveyor, wherein at least one of said food product producing machines outputs food product into an onload position in said second lane; and a shifting mechanism that shifts the food product from said second lane to said first lane.
 2. The system according to claim 1, wherein said first and second lanes move together along a conveyor moving direction and wherein said shifting mechanism is located downstream in a conveyor moving direction from said onload position.
 3. The system according to claim 2, wherein at least one of said plural food product producing machines outputs food product directly into said first lane.
 4. The system according to claim 2, wherein said plural food product producing machines are spaced apart along said combining conveyor and output said food products in a transverse direction perpendicular to said conveyor moving direction.
 5. The system according to claim 4, wherein said food product output from each said food product producing machines comprises a row of food products that is extended in the conveyor moving direction.
 6. The system according to claim 5, wherein said combining conveyor includes a downstream stop in the conveyor moving direction at a shifting position adjacent to the shifting mechanism, wherein said second lane continues to move in the conveyor moving direction beneath a row of food products held stationary by said downstream stop, and said shifting mechanism shifts said row of food products held by said downstream stop into said first lane.
 7. The system according to claim 6, comprising a releasable stop upstream of the downstream stop to delay the arrival of the row from the onload position to the shifting position.
 8. The system according to claim 6, further comprising a formatting station wherein a single column of food products moving in the conveyor moving direction in the first lane is formatted into two or more columns, comprising a second shifting mechanism that alternately shifts groups of food products transversely from the conveyor moving direction from the first lane into a third lane and an adjacent fourth lane.
 9. The system according to claim 8, comprising guides, wherein said third and fourth lanes are merged closely together by said guides and are transported into an accumulating and separating station that groups a grid of food products having two columns and plural rows and transports the grid onto a loading conveyor in a loading station.
 10. The system according to claim 9, comprising a loading station downstream of the formatting station, wherein the loading station is arranged above open top trays arranged to accept the grid of food products in two side-by-side trays, the loading station comprising: a retractable and extendable conveying surface, the conveying surface being arranged above the open top trays and having an end region positionable over the trays and retractable to deposit food products into the trays and a guide assembly arranged to capture and hold the food products on the conveying surface for depositing into the trays when the end region is retracted.
 11. The system according to claim 10, further comprising a pushing assembly arranged within the guide assembly and arranged to push food products from within the guide assembly into the trays after the conveying surface end region is retracted.
 12. The system according to claim 11, wherein the guide assembly comprises a plurality of spaced-apart guide plates movable from an elevated position to a first lowered position to capture the food products on the conveyor, and to a second lowered position below the conveyor and adjacent to the row of open top trays.
 13. The system according to claim 1, wherein the plural food product producing machines comprise food patty forming machines.
 14. The system according to claim 1, wherein the plural food product producing machines comprise food loaf or food slab slicing machines.
 15. The system according to claim 1, wherein said plural food product producing machines comprise multiple output conveyors that output rows of food products extended in the longitudinal direction into the second lane and multiple shifting mechanisms arranged along the combining conveyor are controlled to merge the rows that are placed into the second lane into the first lane so as not to interfere with a row of products already occupying the first lane, to form a single column of food products in the first lane as the first and second lanes move continuously along the longitudinal direction.
 16. The system according to claim 15, comprising a control and sensors communicating with said control, said sensors sensing food products in the first lane to determine clearances in the first lane to command shifting mechanisms in said second lane to shift food products from said second lane into said first lane.
 17. A method of combining rows of food products output from multiple food product producing machines, comprising the steps of: arranging multiple food product producing machines along a combining conveyor having two lanes and transporting in a longitudinal direction; outputting a series of rows of food products from each food product producing machine onto the second lane of the combining conveyor; stopping the rows on the second lane as said first and second lanes continue to move and selectively shifting said rows onto said first lane in order to form a closely packed single column of food products on said first lane.
 18. The method according to claim 17, comprising the further step of formatting the single column into two columns by alternately shifting groups of products laterally of the moving direction of the conveyor.
 19. The method according to claim 18, wherein said two columns are merged closely together and are transported into an accumulating and separating station that groups a grid of food products having two columns and plural rows and transports the grid onto a loading conveyor in a loading station.
 20. The method according to claim 19, arranging open top side-by-side trays in a loading station; arranging a retractable and extendable conveying surface above the open top trays; arranging a guide assembly to capture and hold the food products on the conveyor for depositing into the trays; retracting the conveying surface from below the food products and using the guide assembly loading the food products into the trays. 